Method of on site building

ABSTRACT

The invention concerns a method of building which involves the steps of positioning at least one transportable preformed prestressed channel-shaped body on at least one supporting member, placing a transportable reinforced cementitious loadbearing element at least partly within the channel of the channel-shaped body, and at least partially surrounding the reinforced load-bearing element with settable cementitious material such as concrete. The supporting members can be beams or cantilevered beams and the channel-shaped body can form part of a column. Building structures of this type and units for use in them are also disclosed.

United States Patent [191 De Winter [111 3,846,952 1 Nov. 12, 1974 METHOD OF ON SITE BUILDING [76] Inventor: Marinus De Winter, PO. Box 4364,

Pretoria, South Africa 22 Filed: June 27,1972

21 Appl. No.: 266,736

[56] References Cited UNITED STATES PATENTS 791,875 6/1905 Buente 52/250 X 1,029,530 6/1912 Burchartz 52/439 X 1,038,440 9/1912 Robinson 52/283 X 1,446,275 2/1923 Schulze 52/250 X 1,990,001 2/1935 Rutten 4 52/250 2,284,923 6/1942 Schick 52/250 X 3,113,402 12/1963 Butler 52/414 X 3,290,843 12/1966 Werman 52/414 X 3,562,979 2/1971 Ali-Oglu 52/252 X FOREIGN PATENTS OR APPLICATIONS 767,809 2/1957 Great Britain 52/324 60,077 9/1954 France 52/250 1,006,377 4/1952 Francem. 52/252 559,136 6/1958 Canada... 52/223 R 716,200 9/1954 Great Britain..... 52/223 R 800,326 9/1949 Germany 52/223 R 628,488 8/1949 Great Britain 512/223 R 689,443 2/1930 France 52/223 R Primary ExaminerFrank L. Abbott is nL g miaebL slie Br un Attorney, Agent, or Firm-Karl W. Flocks [57] ABSTRACT 3 Claims, 12 Drawing Figures REINFORCING RODS lN PRESTRESSED PREFABRICATED CONCRETE CONCRETE PATENIEDnnv 12 I974 3' sum 10f a REINFORCING RODS IN PRESTRESSED PREFABRICATED CONCRETE CACT m sn'u CONCRETE REINFORCING RODS IN PRESTRESSED PREFABRICATED CONCRETE CAST IN SITU CONCRETE PRESTRESSED PREFABRICATED CONCRETE (DESIGNATED BY CROSS HATCHING) 24'] PRESTRESSED PREFABRICATED CAST IN SITU CONCRETE (DESIGNATED BY CONCRETE CROSS HATCHING) METHOD OF ON SITE BUILDING FIELD OF THE INVENTION This invention relates to improvements in a method of building, to novel building elements and to building structures produced by the method.

The present invention provides a method of building, which comprises the steps of positioning at least one transportable preformed prestressed channel-shaped body on at least one supporting member, placing a transportable reinforced cementitious load-bearing element at least partly within the channel of the channelshaped body, and at least partially surrounding the reinforced load-bearing element with settable cementitious material.

The preformed prestressed channel-shaped body may be any suitable cementitious channel-shaped body. One particular novel channel-shaped body is preformed and prestressed to a camber. Accordingly, the invention further provides as a component of loadbearing structure, a transportable reinforced cementitious channel-shaped body prestressed to a camber to such an extent that when supported at its ends and bearing its own weight and dead weight only, it is substantially true. Thus, when the transportable reinforced cementitious channel-shaped body is supported in position at its ends, there will be substantially no camber.

The novel channel-shaped body can be used as a soffit which is true when seated on its end supports. The reinforcing may be any material capable of resisting tensile stresses, for example reinforcing bars, structural steel sections or, prestressed concrete elements.

The sides of the channel-shaped body may be at right angles to the base (i.e., the soffit) or may be inclined thereto. The channel space may be partitioned to form compartments which may be filled with concrete during building or left void. The partitioning can be so positioned that the space between one pair of adjacent partitions is filled with concrete, and the space between the next pair of partitions is left void. The space which is filled with concrete will be where stresses developed by elastic behaviour of the composite structure have to be resisted. Permanent covering may be provided over the partitions where the voids are to be. In this way wet concrete or other cementitious material is prevented from entering these parts, with a consequential saving in cost.

The reinforced cementitious load-bearing element provided by the invention may be of any suitable crosssection, for example of inverted T-shape or rectangular. Any of the reinforcing materials indicated above for the channel-shaped body may be used in the loadbearing element. It is a tensile element and can be used in positions where ordinary steel reinforcing normally is used. The reinforced cementitious load-bearing element may be prestressed.

The reinforced cementitious load-bearing element can be used, according to the method of the invention, in the channel-shaped bodies at any point where tensile stresses are liable to occur, for example when the channel-shaped bodies form part of a column, a floor structure of a beam.

In one embodiment, when the prestressed channelshaped bodies are used to make a column, the reinforced cementitious load-bearing element can be positioned adjacent to the base of the channel. The column can be built up of a plurality of pairs of substantially vertical channel-shaped bodies in face-to-face relationship (i.e., each body of a pair facing the other body of the pair), with the centre of the column thus defined filled with concrete and appropriately spaced reinforced cementitious load-bearing elements. Conveniently the channel-shaped bodies on one side may be stepped with respect to those on the other side (e.g., by half a length of a channel-shaped body) to avoid a straight joint right across the column. The reinforced cementitious load-bearing elements conveniently straddle the joint between adjacent channel-shaped bodies.

In a second embodiment, the supporting member may be beams. The beams may have both ends resting on supports (e.g., columns or foundation walls) or may be cantilevered.

In the second embodiment a pair of preformed prestressedchannel-shaped bodies rest across three more beams in end to end relationship with their facing ends on a single beam, and with a reinforcing cementitious load-bearing element straddling the two channelshaped bodies. The reinforced cementitious loadbearing element may be positioned so that it is within the channels but extends slightly above the height of the sides of the channels. The facing ends of the channel-shaped bodies may abut against one another or may be spaced from one another while resting on the same beam. If desired, the channel-shaped bodies can be so formed that their ends abut against each other but their bottom surfaces (soffits), while resting on the beam, are spaced from each other. Any space between the soffits may be filled with concrete at the same time as the space around the reinforced cementitious loadbearing element is filled to provide continuity and produce a homogeneous isotropic joint.

Conveniently, a plurality of prestressed channelshaped bodies are provided in abutting relationship with their bottom surfaces (i.e., the soffits) forming a ceiling and their upper surfaces forming a support for a floor. If desired, the sides of the channel-shaped bodies may converge inwardly so that the bodies only abut towards the bottom thereof. The channel-shaped bodies may be prestressed to a camber to such an extent that when resting on the beams and bearing their own weight and dead weight only, they are substantially true.

As indicated above, the channel-shaped bodies resting on the beams may contain partitioning and covering at places where no stresses develop. The cementitious load-bearing element may rest with its ends just on the covering with the covering beneath the load bearing element or the covering notched to receive the load bearing element. The space in the channel-shaped bodies around the cementitious load-bearing element, and exterior of the covering and partitioning is filled with settable cementitous material, such as concrete to anchor it. By providing voids beneath the covering at places where no stresses develop, a saving in concrete results, and thus a saving in cost.

In another embodiment, the preformed prestressed channel-shaped body may form a beam. In this embodiment, the prestressed cementitious load-bearing element(s) can be inserted in the channel to resist stresses, and then concreted in. The beam may be around a door or window or may even provide a support for cantilever panels.

For example, in one construction, a pair of adjacent supporting columns can have a channel-shaped body extending across and into them'to define a beam. A transportable reinforced load-bearing element can extend outwardly from an end of the channel through one of the columns in cantilever fashion. This load-bearing element can be at least partly surrounded by concrete, which may conveniently be cast in one step to provide a strong anchoring surround for the element within both the column and the channel-shapedelement. A parallel pair of cantilevered load-bearing elements may be provided in similar manner and channel-shaped bodies may rest across the three load-bearing elements with their facing ends on the central cantilevered loadbearing element and their soffits defining the ceiling of the floor below. The floor on the level of the cantilevered load-bearing elements may be concreted in, utilising load-bearing elements to straddle the ends of the channel shaped elements, as described above.

The invention also provides structures built by the method described. In particular there is provided a building structure which includes at least one transportable preformed prestressed channel-shaped body, and a transportable reinforced cementitious loadbearing element positioned at least partly within the channel and at least partially surrounded by anchoring cementitious material.

In one preferred embodiment, the building structure comprises a column into which a channel-shaped body extends from one direction and out of which a cantilevered transportable reinforced cementitious loadbearing element extends from the opposite direction,

the load-bearing element continuing into the channel of the channel-shaped element and being at least partially surrounded in the column and the channelshaped element by anchoring cementitious material.

The invention is illustrated by reference to the accompanying drawings in which:

FIG. 1 is a plan view of part of a floor built according to the invention,

FIG. 2 is a section along IIII of FIG. 1;

FIG. 3 is a section along III-III of FIG. 2;

FIG. 4 is a section along IV-IV of FIG. 2;

FIG. 5 is a section along VV of FIG. 2;

FIG. 6 is a section through a floor built, on a cantilevered beam, according to the invention;

FIG. 7 is a section through the cantilever beam at position VII-VII of FIG. 6;

FIG. 8 is a section through VIII-VIII of FIG. 6;

FIG. 9 is a cross-section through an ordinary beam built according to the invention;

FIG. 10 is a section along XX of FIG. 9;

FIG. 11 is a section along XIXI of FIG. 9;

FIG. 12 is a perspective view partially in section of a structure somewhat like the embodiment shown in FIGS. 1-5, inclusive.

In FIGS. 1 to 5 and FIG. 12, a column shown generally at comprises a plurality of pairs of facing channel-shaped bodies 10, 10.1, 12 etc. with adjacent facing bodies stepped with respect to one another. Positioned inside the channel-shaped bodies at the joints are reinforced cementitious load-bearing elements 14, 14.1 etc. The remainder of the interior of the column is filled with concrete 16. A beam 28, of channel shape extends between the column 20 and another column (not shown). Other parallel beams (not shown) exist between adjacent columns not shown).

A plurality of parallel abutting preformed channelshaped bodies 22, 22.1, 22.2 etc. and 24, 24.1, 24.2 etc. rest across the parallel beams. The bodies 22 and 24, 22.1 and 24.1, 22.2 and 24.2, etc. are aligned with their facing ends resting on the beam '18. The sides 25, 25.1 etc abut against each other but the soffits are spaced from one another. The sides 25 of the bodies taper inwardly so their lower surfaces are flush to form a ceiling.

Reinforced cementitious load-bearing elements 28, 28.1, 28.2 etc. are placed across the ends of the channel-shaped bodies 22 and 24, 22.1 and 24.1, 22.2 and 24.2 etc. except in FIG. 12 where these load-bearing elements are not shown because of the corner structure depicted here. Partitioning is shown at30, 30.1 and supports lightweight covering 32, 32.1 etc. (see FIG. 2) to define voids 31, 33. Then the space around the elements 28, 28.1 etc., is filled in with concrete.

The beam 18 similarly incorporates partitioning 34 and lightweight covering 36 to define void 37.

In FIGS. 6 to 8, a column is shown at 40 and a cantilevered beam shown at 42. The cantilevered beam 42 is a transportable reinforced load-bearing element which extends through the column 40 into the channel of channel-shaped body 43. The channel-shaped body 43 extends as a beam between and into the column 40 and another column (not shown). Channel-shaped bodies 44, 44.1, 44.2 and 46, etc. rest on the cantilevered beam 42 and beam 43. The other ends of the bodies 44, 44.1, 44.2 and 46 etc., rest on their parallel beams (not shown).

The bodies 44, 46 etc. contain partitioning 48, 50 and lightweight covering 52, 54. Concrete is poured into the channels after reinforced cementitious loadbearing elements 56, 56.1 etc., are positioned so that they straddle the bodies 44, 46, etc. Thereafter, the spaces remaining are filled with concrete 58.

In the figures (i.e., FIGS. 2, 5, 6 and 8) the loadbearing elements are shown resting on notched partitions with openings in the lightweight covering sufficient to receive the load-bearing elements. The openings are thus closed by the load-bearing elements to maintain the voids therebeneath clear of concrete. Optionally, but not shown, it would be possible to merely rest the load-bearing elements on top of the lightweight covering and partition avoiding any notching.

In FIGS. 9 to 11, one side of a frame comprises channel-shaped bodies 60, 62 etc. A further channel-shaped body 64 is supported on the sides of the frame. The body 64 contains partitioning 66 and lightweight covering 68. A reinforced cementitious load-bearing element (not visible) is provided at a point of stress and concreted in.

The invention enables a structure to be built from the prestressed channel-shaped bodies and load-bearing elements and concreted together on site. As can be seen, the concrete may function solely as an isotropic material with the top thereof accounting for compression stresses and the prestressed elements accounting for the tensile stresses. The concrete beneath the prestressed elements can account for shear and additional stresses at the columns. Inclined sides 25 to the bodies 24, etc., enable good bonding to be obtained.

I claim:

1. A method of on-site building, which comprises the steps of providing at least one open-topped supporting member having upstanding sides and a hollow interior between said sides;

providing at least one transportable preformed, prestressed channel-shaped body, comprising a soffit and channel sides defining a space therebetween;

partitioning between and along said channel sides at t a predetermined distance from the end of the soffit forming a hollow enclosure with the soffit and sides of the channel-shaped body; positioning said transportable preformed prestressed channel-shaped body with the soffit resting directly on an upstanding side of said open-topped supporting member; at least partially filling continuous space of said opentopped supporting member and channel-shaped body with settable cementitious material and a transportable reinforced cementitious load-bearing element, the transportable reinforced cementitious load-bearing element being placed at least partly within the channel of the channel-shaped body and being at least partially surrounded with the settable cementitious material; and permitting the settable cementitious material to set, thereby bonding the said supporting member, the preformed, prestressed channel-shaped body and the transportable reinforced cementitious load-bearing element together with a continuous mass of set cementitious material while leaving an air space below the partitioning on the side which cannot be reached by the settable cementitious material. 2. A method of on-site building, which comprises the steps of providing a pair of spaced-apart open-topped supporting members, each having upstanding sides and a hollow interior between said sides;

providing at least one transportable preformed, prestressed channel-shaped body, comprising a soffit and channel sides defining a space therebetween;

steps of providing three spaced-apart open-topped supporting members, each having upstanding sides and a hollow interior between said sides;

providing at least one pair of longitudinally-aligned transportable preformed, prestressed channelshaped bodies, each comprising a soffit and channel sides defining a space therebetween;

partitioning and along said channel at a predetermined distance from the ends of the soffit forming a hollow enclosure with the soffit and sides of the channel-shaped body;

positioning said transportable preformed, prestressed channel-shaped body with an adjacent end of each soffit resting directly on a side of the middle opentopped supporting member and the far ends of the soffits on a side of the other open-topped supporting members;

at least partially filling continuous space of opentopped supporting members and channel-shaped bodies with settable cementitious material and a transportable reinforced cementitious load-bearing element, the transportable reinforced cementitious load-bearing element being placed at least partly within the channels of the channel-shaped bodies straddling the adjacent ends of the pair of adjacent channel-shaped bodies and being at least partially surrounded with the settable cementitious material,

and permitting the settable cementitious material to set, thereby bonding the said middle supporting member, the pari of preformed, prestressed channel-shaped bodies and the transportable reinforced cementitious load-bearing element together with a continuous mass of set cementitious material, while leaving an air space below the partitioning on the side which cannot be reached by the settable cementitious material. 

1. A method of on-site building, which comprises the steps of providing at least one open-topped supporting member having upstanding sides and a hollow interior between said sides; providing at least one transportable preformed, prestressed channel-shaped body, comprising a soffit and channel sides defining a space therebetween; partitioning between and along said channel sides at a predetermined distance from the end of the soffit forming a hollow enclosure with the soffit and sides of the channelshaped body; positioning said transportable preformed prestressed channelshaped body with the soffit resting directly on an upstanding side of said open-topped supporting member; at least partially filling continuous space of said open-topped supporting member and channel-shaped body with settable cementitious material and a transportable reinforced cementitious load-bearing element, the transportable reinforced cementitious load-bearing element being placed at least partly within the channel of the channel-shaped body and being at least partially surrounded with the setTable cementitious material; and permitting the settable cementitious material to set, thereby bonding the said supporting member, the preformed, prestressed channel-shaped body and the transportable reinforced cementitious load-bearing element together with a continuous mass of set cementitious material while leaving an air space below the partitioning on the side which cannot be reached by the settable cementitious material.
 2. A method of on-site building, which comprises the steps of providing a pair of spaced-apart open-topped supporting members, each having upstanding sides and a hollow interior between said sides; providing at least one transportable preformed, prestressed channel-shaped body, comprising a soffit and channel sides defining a space therebetween; partitioning between and along said channel sides at a predetermine distance from the ends of the soffit forming a hollow enclosure with the soffit and sides of the channel-shaped body; positioning said transportable preformed, prestressed channel-shaped body with the ends of the soffit resting directly on that side of each open-topper supporting member which is nearer to the other supporting member; at least partially filling continuous space of said open-topped supporting members and channel-shaped body with settable cementitious material and a transportable reinforced cementitious load-bearing element, the transportable reinforced cementitious load-bearing element being placed at least partly within the channel of the channel-shaped body and being at least partially surrounded with the settable cementitious material; and permitting the settable cementitious material to set, thereby bonding the said supporting member, the preformed, prestressed channel-shaped body and the transportable reinforced cementitious load-bearing element together with a continuous mass of set cementitious material while leaving an air space below the partitioning on the side which cannot be reached by the settable cementitious material.
 3. A method of on-site building, which comprises the steps of providing three spaced-apart open-topped supporting members, each having upstanding sides and a hollow interior between said sides; providing at least one pair of longitudinally-aligned transportable preformed, prestressed channel-shaped bodies, each comprising a soffit and channel sides defining a space therebetween; partitioning and along said channel at a predetermined distance from the ends of the soffit forming a hollow enclosure with the soffit and sides of the channel-shaped body; positioning said transportable preformed, prestressed channel-shaped body with an adjacent end of each soffit resting directly on a side of the middle open-topped supporting member and the far ends of the soffits on a side of the other open-topped supporting members; at least partially filling continuous space of open-topped supporting members and channel-shaped bodies with settable cementitious material and a transportable reinforced cementitious load-bearing element, the transportable reinforced cementitious load-bearing element being placed at least partly within the channels of the channel-shaped bodies straddling the adjacent ends of the pair of adjacent channel-shaped bodies and being at least partially surrounded with the settable cementitious material, and permitting the settable cementitious material to set, thereby bonding the said middle supporting member, the pari of preformed, prestressed channel-shaped bodies and the transportable reinforced cementitious load-bearing element together with a continuous mass of set cementitious material, while leaving an air space below the partitioning on the side which cannot be reached by the settable cementitious material. 